GEA HGX34P Series User manual

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engineering for a better world
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GEA Compressor HGX34P 2-pole
Assembly instructions
HGX34P/255-2 HGX34P/315-2 S
HGX34P/255-2 A HGX34P/315-2 S A HGX34P/380-2
HGX34P/315-2 HGX34P/315-2 A K HGX34P/380-2 A
HGX34P/315-2 A HGX34P/315-2 S A K HGX34P/380-2 A K

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About these instructions
Read these instructions before assembly and before using the compressor. This will avoid misunder-
standings and prevent damage. Improper assembly and use of the compressor can result in serious
or fatal injury.
Observe the safety instructions contained in these instructions.
These instructions must be passed onto the end customer along with the unit in which the compres-
sor is installed.
GEA Bock GmbH
72636 Frickenhausen
GEA Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Telephone [phone]
Fax [phone]
[email protected]
www.gea.com
Manufacturer
Contact

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Contents Page
1 Safety 4
1.1 Identification of safety instructions
1.2 Qualifications required of personnel
1.3 General safety instructions
1.4 Intended use
2 Product description 6
2.1 Short description
2.2 Name plate
2.3 Type key
3 Areas of application 8
3.1 Refrigerants
3.2 Oil charge
3.3 Limits of application
3.4 Limits of application K Design
4Compressor assembly 11
4.1 Storage and transport
4.2 Setting up
4.3 Maximum permissible inclination
4.4 Pipe connections
4.5 Pipes
4.6 Laying suction and pressure lines
4.7 Operating the shut-off valves
4.8 Operating mode of the lockable service connections - suction line valve
4.9 Operating mode of the lockable service connections - discharge line valve
5 Electrical connection 15
5.1 Information for contactor and motor contactor selection
5.2 Connection of the driving motor - star circuit
5.3 Connection of the driving motor - part-winding circuit
5.4 Circuit diagram
5.5 Electronic trigger MP 10
5.6 Connection of the electronic trigger MP 10
5.7
External connection MP10
5.8 Functional test of the electronic trigger unit MP 10
6 Commissioning 22
6.1 Preparations for start-up
6.2 Pressure strength test
6.3 Leak test
6.4 Evacuation
6.5 Refrigerant charge
6.6 Start-up
6.7 Avoid slugging
7 Maintenance 24
7.1 Preparation
7.2 Work to be carried out
7.3 Spare parts recommendation
7.4 Accessories
7.5 Extract from the lubricants table
7.6 Decommissioning
8 Technical data 26
9 Dimensions and connections 28
10 Declaration of installation 30
11 Service 31

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1|Safety
1.2 Qualicationsrequiredofpersonnel
DANGER Indicates a dangerous situation which, if not avoided,
will cause immediate fatal or serious injury.
WARNING Indicates a dangerous situation which, if not avoided,
may cause fatal or serious injury.
CAUTION Indicates a dangerous situation which, if not avoided,
may cause fairly severe or minor injury.
ATTENTION Indicates a situation which, if not avoided,
may cause property damage.
INFO Important information or tips on simplifying work.
WARNING Inadequatelyqualiedpersonnelposestheriskofaccidents,the
consequencebeingseriousorfatalinjury.Workoncompressors
isthereforereservedforpersonnelwhichisqualiedtoworkon
pressurized refrigerant systems:
• For example, a refrigeration technician, refrigeration mechatronic
engineer. As well as professions with comparable training, which
enables personnel to assemble,install,maintain and repair refrigeration
and air-conditioning systems. Personnel must be capable of assessing
the work to be carried out and recognising any potential dangers.
1.1 Identicationofsafetyinstructions:

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1|Safety
1.4 Intended use
1.3 Safety instructions
WARNING Risk of accidents.
Refrigerating compressors are pressurised machines and as such
call for heightened caution and care in handling.
The maximum permissible overpressure must not be exceeded,
even for testing purposes.
Risk of burns!
- Depending on the operating conditions, surface temperatures of
over 60°C on the discharge side or below 0°C on the suction side
can be reached.
- Avoid contact with refrigerant necessarily.
Contact with refrigerant can cause severe burns and skin
damage.
WARNING The compressor may not be used in potentially explosive
environments!
These assembly instructions describe the standard version of the compressor named in the title man-
ufactured by GEA. GEA refrigerating compressors are intended for installation in a machine (within
the EU according to the EU Directives 2006/42/EC Machinery Directive, 97/23/EC Pressure Equipment
Directive).
Commissioning is permissible only if the compressor has been installed in accordance with these as-
sembly instructions and the entire system into which it is integrated has been inspected and approved
in accordance with legal regulations.
The compressors are intended for use in mobile refrigeration systems in compliance with the limits
of application.
Only the refrigerant specied in these instructions may be used.
Any other use of the compressor is prohibited!

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• Semi-hermetic four-cylinder reciprocating compressor with oil pump lubrication.
• Optional in light weight aluminium design
• Suction gas cooled drive motor
2|Product description
Fig. 1
2.1 Short description
Fig. 2
Oil sight glass
Valve plate
Cylinder cover
Discharge
line valve
Oil pump
Terminal box
Suction
line valve
Drive section
Motor section
Dimension and connection values can be found in Chapter 9
Transport eyelet
Name plate
1
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2|Product description
/
HG 43 P 315-2 S AK X
2.2 Name plate (example)
2.3 Type key (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled)
²) X
- Ester oil charge
³) Additional declaration for Pluscom compressors
4) S - More powerful motor e.g. air-conditioning applications
Version
Aluminium lightweight design
Motor variant 4)
Number of poles
Swept volume
³)
Numbers of cylinders
Size
Oil charge ²)
Series ¹)
1
2
3
4
5
13
12
7
11
6
10
8
9
19/28 SE 55
66,1
79,3
IP66
HGX34P/380-2 A
38,0
Y: 172 A
380-420V Y -3- 50HZ
440-480V Y -3- 60HZ
2900
3480
AS38125A001
Fig. 3
1 Type designation 6 Voltage, circuit, frequency
2 Machine number 7 Nominal rotation speed
3 maximum operating current 8 Displacement
4 Starting current (rotor blocked) 9 Voltage, circuit, frequency
5 ND (LP): max. permissible operating 10 Nominal rotation speed
pressure (g) Low pressure side 11 Displacement
HD (HP): max. permissible operating 12 Oil type lled at the factory
pressur e(g) High pressure side 13 Terminal box protection type
Observe the limits of application Electrical accessories can change
diagrams! the IP protection class!
50 Hz
}
60 Hz
}
GEA Bock GmbH
72636 Frickenhausen, Germany

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3|Areas of application
The compressors are factory-lled with the following oil type:
- FUCHS Reniso Triton SE 55
Compressors with ester oil charge (FUCHS Reniso Triton SE 55) are marked with an X in the type
designation (e.g. HGX34P/380-2 A).
3.1 Refrigerants
• HFKW / HFC: R134a, R407C
3.2 Oil charge
INFO For refilling, we recommend the above oil types.
Alternatives: see lubricants table, Chapter 7.5.
ATTENTION Compressor operation is possible within the operating limits
showninthediagrams.Pleasenotethesignicance
of the shaded areas. Thresholds should not be selected as design
or continuous operation points.
- Permissible ambient temperature (-20°C) - (+60°C)
- Max. permissible discharge end temperature 140°C.
- Max.permissibleswitchingfrequency8x/h.
- A minimum running time of 3 min. steady-state condition
(continuous operation) must be achieved.
For operation with capacity regulator:
- Continuous operation, when the capacity regulator is activated, is
not permissible and can cause damage to the compressor.
- The suction gas superheat temperature may need to be reduced or
set individually when operating near to the threshold.
- When the capacity regulator is activated, the gas velocity in the
systemcannotundercertaincircumstancesensurethatsufci-
ent oil is transported back to the compressor.
Foroperationwithfrequencyconverter:
- Control range of the compressor 15 - 50 Hz
(K Design 15 - 60 Hz).
- The maximum current and power consumption must not be
exceeded.Inthecaseofoperationabovethemainsfrequency,
the application limit can therefore be limited
- Use a heat protection thermostat.
- Oilreturnatlowfrequencymustbesupplied.
When operating in the vacuum range, there is a danger of air entering
on the suction side. This can cause chemical reactions, a pressure
rise in the condenser and an elevated compressed-gas temperature.
Prevent the ingress of air at all costs!
3.3 Limits of application
ATTENTION The oil level must be in the
visible part of the sight glass;
damage to the compressor is
possible if overfilled or under-
filled!
max.
min.
0,7 Ltr.
oil level
Fig. 4
~
~

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3|Areas of application
Design for other
rangesonrequest
Unrestricted
application range
Fig. 5
Fig. 6
HGX34P/315-2 (A) not suitably for R407C.
Evaporating temperature (°C)
Condensing temperature (°C)
Suction gas temperature (°C)
R134a
50 Hz
R407C
50 Hz
Unrestricted
application range
1HGX34P/380-2 (A)
observe the operating limits
Evaporating temperature (°C)
Condensing temperature (°C)
Suction gas temperature (°C)
Max. permissible operating
pressure (LP/HP)1): 19/28 bar
1) LP = Low pressure
HP = High pressure

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3|Areas of application
3.4 Limits of application K Design (60 Hz)
• HFKW / HFC: R134a, R407C
Fig. 7
Fig. 8
R134a
60 Hz
R407C
60 Hz 1HGX34P/380-2 (A) K
observe the operating limits
Design for other
rangesonrequest
Unrestricted
application range
Evaporating temperature (°C)
Condensing temperature (°C)
Suction gas temperature (°C)
Unrestricted
application range
Evaporating temperature (°C)
Condensing temperature (°C)
Suction gas temperature (°C)
Max. permissible operating
pressure (LP/HP)1): 19/28 bar
1) LP = Low pressure
HP = High pressure

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Amax. 30°,
max. 2 minutes
amax. 15°,
continuous
operation
4|Compressor assembly
4.2 Setting up
Setup on an even surface or frame with sufcient load-
bearing capacity.
Single compressor preferably on vibration damper.
Duplex and parallel circuits always rigid.
Provide adequate clearance for maintenance work.
Ensure adequate compressor ventilation.
Do not use in a corrosive, dusty, damp atmosphere or a
combustible environment.
Fig. 11
Fig. 12
Fig. 13
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A
B
Tol.-Ang. DIN ISO 2768-mK
Ra Rz
Maß Passung
Freigabe
Alternativbezug:
Baumustergeprüft
Teil inaktiv
Lieferantenzeichnung
-
-
K.-Auftrag:
PL:
Zeichnung ungültig
Entwicklungsstand
Teil keine Serie
120
400
±0.5
über 0.5
bis 6
Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
-
-
Unbemaßte Radien:
-
Diese Zeichnung ist unser Eigentum!
Sie darf ohne unsere Genehmigung weder nach-
gebildet, vervielfältigt, oder Dritten Personen zu-
gänglich gemacht werden. Der Nachbau nach
dieser Zeichnung, oder an Hand der nach dieser
Zeichnung hergestellten Gegenstände durch den
Abnehmer oder Dritte ist nicht gestattet.
Wir behalten uns alle Rechte, gemäß DIN ISO 16016
an dieser Zeichnung vor.
Bearb.
Datum
Änderungs-Nr.
Werkstoff:
Ausgangsteil, bzw. Rohteil:
-
-
Gepr.
Name Datum
19.04.
Werkstückkanten
DIN ISO 13715
Ersatz für:
Ersetzt durch:
Erstellt
2010
Geprüft
-
Kurz
Zone
1/x
Oberflächenbehandlung / Härte:
-
Blatt:
Änderungsbeschreibung
400
Benennung:
±0.8
1000
30 6
-
±0.3
120
30
±0.2
Zeichn.-Nr. Teile-Nr.
Oberflächenangaben ISO 1302
x.xxxx-xxxxx.x
Zust.
Gußtoleranzen:
Gewicht: (kg)
±0.1
Maßstab:
1:1
Wasserwaage
für Indesign
Der Lieferant muß sicherstellen, dass die Ware in
einwandfreiem Zustand angeliefert wird (Korrosions-
schutz, Verpackung für sicheren Transport).
Rz 25
Rz 160
s
25
z y x w u t
0,05
Rz 1,6
0,3
0,7
1,6
2
Rz 16
6,3
Rz 63
Rz 6,3
Rz 12,5
F:\user\kurz\3D Sachen\3D Teile\Zeichnungen\Wasserwaage
4.3 Maximum permissible inclination
A
a
A
aa
A
a
A
Fig. 14
INFO Newcompressorsarefactory-lledwithinertgas(3barnitrogen).
Leave this service charge in the compressor for as long as possible
and prevent the ingress of air. Check the compressor for transport
damage before starting any work.
ATTENTION Poor lubrication can damage the compressor. Respect the stated
values
ATTENTION Fittings (e.g. pipe holders, additional units, mounting parts etc.) on
the compressor are not permissible!
?
4.1 Storage and transport
Use transport eyelet.
Do not lift manually!
Use lifting gear!
Storage at (-30°C) - (+70°C), maximum permissible relative humidity
10% - 95%, no condensation
Do not store in a corrosive, dusty, vaporous atmosphere or in a com-
bustible environment.
Fig. 10
Fig. 9

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4|Compressor assembly
4.4 Pipe connections
The pipe connections have graduated inside diameters so that pipes
with standart millimetre and inch dimensions can be used.
The connection diameters of the shut-off valves are rated for maximum
compressor output. Theactualrequiredpipecrosssectionmustbe
matched to the output. The same applies for non-return valves.
Fig. 15: graduated
internal diameter
4.5 Pipes
4.6 Laying suction and pressure lines
A rule of thumb: Always lay the rst pipe section starting from the shut-off valve downwards
and parallel to the drive shaft.
ATTENTION Improperly installed pipes can cause cracks and tears, the result
being a loss of refrigerant.
INFO Proper layout of the suction and discharge lines directly after
the compressor is integral to the system’s smooth running and
vibration behaviour.
Rigid
fixed point
As short as
possible
Fig. 16
ATTENTION Damage possible.
Do not solder as long as the compressor is under pressure.
Superheating can damage the valve.
Remove the pipe supports therefore from the valve for soldering
and accordingly cool the valve body during and after soldering.
Only solder using inert gas to inhibit oxidation products (scale).
Pipes and system components must be clean and dry inside and free of scale, swarf and layers of
rust and phosphate. Only use air-tight parts.
Lay pipes correctly. Suitable vibration compensators must be provided to prevent pipes being
cracked and broken by severe vibrations.
Ensure a proper oil return.
Keep pressure losses to an absolute minimum.

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Valve spindle seal
Release
Tighten
4|Compressor assembly
Fig. 17 Fig. 18
4.8 Operating mode of the lockable service connections
Suction line valve
Before opening or closing the shut-off valve, release the valve spindle seal by approx. ¼ of a turn
counter-clockwise.
After activating the shut-off valve, re-tighten the adjustable valve spindle seal clockwise.
4.7 Operating the shut-off valves
Pipe connection
Pipe connection
Fig. 19
Opening the shut-off valve:
Spindle: turn to the left (counter-clockwise) as far as it will go.
—> Shut-off valve completely opened / service connection closed.
The connection which cannot be shut off is intended for safety devices.
Fig. 20
Opening the service connection
Spindle: Turn ½ - 1 turn clockwise.
—> Service connection opened / shut-off valve opened.
The connection which cannot be shut off is intended for safety devices.
Service connec-
tion closed
Connection
blocked
Spindle
Connection cannot be
shut off
Connection cannot be
shut off
Service connec-
tion opened
Spindle Connection
open
Compressor
Compressor
After activating the spindle, generally t the spindle protection cap again and tighten with 14-16 Nm.
This serves as a second sealing feature during operation.

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4.9 Operating mode of the lockable service connections
Discharge line valve
4|Compressor assembly
Pipe connection
Pipe connection
Fig. 21
Opening the shut-off valve:
Spindle: turn to the left (counter-clockwise) as far as it will go.
—> Shut-off valve completely opened / service connection closed.
Fig. 22
Opening the service connection
Spindle: Turn ½ - 1 turn to the right clockwise.
—> Service connection opened / shut-off valve opened.
Service connec-
tion closed
Connection
blocked
Spindle
Service connec-
tion opened
Spindle Connection
open
Compressor
Compressor
After activating the spindle, generally t the spindle protection cap again and tighten with 14-16 Nm.
This serves as a second sealing feature during operation.

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5|Electrical connection
5.1 Information for contactor and motor contactor selection
All protection equipment, switching and monitoring devices must comply with the local safety regula-
tions and established specications (e.g. VDE) and regulations as well as the manufacturer’s specica-
tions. Motorprotectionswitchisrequired! Motor contactors, feed lines, fuses and motor protection
switches must be rated according to the maximum operating current (see name plate).
Use the following overload protection device:
A current-dependent time-delayed overload protection device for monitoring of all three phases, not
set higher than the rated current of the machine, which must respond at 1.2 times the set current
within 2 hours and must not have responded at 1.05 times the set current within 2 hours, or another
comparable device.
INFO Connect the compressor motor in accordance with the circuit diagram
(see inside of terminal box).
Use suitable cable entry point of the correct protection type (see
name plate) for routing cables into the terminal box. Insert the strain
reliefs and prevent chafe marks on the cables.
Compare the voltage and frequency values with the data for the
mains power supply.
Only connect the motor if these values are the same.
DANGER Risk of electric shock! High voltage!
Only carry out work when the electrical system is disconnected
from the power supply!
5 Electrical connection
ATTENTION When attaching accessories with an electrical cable, a minimum
bending radius of 3 x the cable diameter must be maintained for
laying the cable.

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5.2 Connection of the driving motor with star circuit
Designation on the name plate Sticker on the terminal box
Y
Star-delta start-up is only possible on 230 V voltage supply. Example:
400 V Y
Direct start only
Elektrischer Anschluss Electrical connection Raccordement électrique ∆/ Y
96027-11.06-DGbF
∆
Niedere Spannung
Low voltage
Bas voltage
Y
Hohe Spannung
High voltage
Haut voltage
L3
L1 L2
L3
L1 L2
Y
5|Electrical connection

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5.3 Connection of the driving motor with part winding circuit
Designation on the name plate Sticker on the terminal box
Y/YY
400 V
Direct start YY with bridges PW - start-up Y/YY without bridges
Example:
L3L1 L2
U1
V1 W1
W2
U2
V2
L3L1 L2
U1
V1 W1
W2
U2
V2
L3
L1 L2
PW II
PW I
5|Electrical connection
Anschlus sdesAntriebsmotors
Der Motor ist serienmäßig in ∆ / Y - Ausführung geschaltet.
Bezeichnung auf dem Typschild: ∆ / Y
Kennzeichnung auf gelbem Aufkleber des Klemmen-
kastens (siehe Abbildung):
Verdichter mit dieser Kennzeichnung sind im Spannungsbereich ∆
für Stern-Dreieck-Anlauf geeignet.
Der Anschluss im Klemmenkasten ist werkseitig für Direktstart (Y) vorgesehen.
Direktstart (Beispiel für Motor 230 V ∆ / 400 V Y)
Klemmbrett mit eingelegten Brücken für den Direktstart:
a) bei niederer Spannung b) bei höherer Spannung
(230 V ∆ / 3~) (400 V Y/ 3~):
Abb.: schemati sch
Y/YY (PW)
ATTENTION Failure to do this results in opposed rotary elds and results in
damage to the motor. After the motor starts up via partial winding
1, partial winding 2 must be switched on after a maximum delay
of one second . Failure to comply can adversely affect the service
life of the motor.

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         

  






















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
         





 







 




  

 







 










5.4 Circuit diagramm for direct start 400 V Y
Fig. 23 Compressor terminal box
R1 Cold conductor PTC sensor motor winding
R2 Thermal protection thermostat (PTC sensor)
F1 Load circuit safety switches
F2 Control power circuit fuse
F3 Safety chain (high/low pressure monitoring)
B1 Release switch (thermostat/pressostat)
Q1 Main switch

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96116-01.2016-DGbFE
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S1 Control voltage switch
M1 Compressor motor
K1 Compressor contactor
MP10 Electronic trigger unit MP 10
E Oil sump heater
X3 Terminal strip in terminal box
XSS Terminal strip in the external switch cabinet
A1 Alarm Motor protection
A2 Overheating R1, R2
A3 Alarm high pressure
XSS Terminal strip in the external
switch cabinet

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5|Electrical connection
Temperature monitoring connections:
Motor winding: Terminals 1 - 2
Thermal protection thermostat: Terminals 3 - 4
Restart prevention: Terminals 5 - 6
5.5 Electronic trigger unit MP 10
The compressor motor is tted with cold conductor temperature sensors (PTC) connected to the
electronic trigger unit MP 10 in the terminal box. Readiness to operate is signalled by the H3 LED
(green) after the power supply is applied. In the case of excess temperature in the motor winding, the
unit switches off the compressor and the H1 LED lights red.
The hot gas side of the compressor can also be protected against overtemperature using a thermal
protection thermostat (accessory). The H2 LED (red) is provided for the protection function.
The unit trips when an overload or inadmissible operating conditions occur. Find and remedy
the cause.
5.6 Connection of the trigger unit MP 10
Anschluss des Auslösegerätes MP 10
Der elektrische Anschluss des MP 10 ist gemäß Schaltplan vorzunehmen. Das Aus-
lösegerät ist mit einer Sicherung (F) von max. 4 A träge abzusichern. Um die Schutz-
funktion zu gewährleisten, ist das Auslösegerät als erstes Glied in den Steuerstrom-
kreis zu installieren.
Anschlüsse Temperaturüberwachung:
Motorwicklung: Klemmen 1 - 2
Heißgasseite: Klemmen 3 - 4
Klemmen 1 - 6 am Auslösegerät MP 10 und Klemmen PTC 1 und PTC 2 am
Verdichterklemmbrett dürfen nicht mit Netzspannung in Berührung kommen.
Das Auslösegerät und die PTC-Fühler werden sonst zerstört.
Klemmbrett
Abb.: schematisch
PTC1 PTC2
Terminal box
Fig. 24
INFO Theunithasarestartpreventiondevice.Afteryouhaverectiedthe
fault, interrupt the mains voltage. This unlocks the restart prevention
device and the LEDs H1 and H2 go out.
ATTENTION
Terminals 1 - 6 on the trigger
unit MP 10 and terminals PTC
1 and PTC 2 on the compres-
sor terminal board must not
come into contact with mains
voltage. This would destroy the
trigger unit and PTC sensors.
The supply voltage at L1-N
(+/- for DC 24 V version) must
be identical to the voltage at
terminals 11, 12, 14 and 43.
INFO Connect the trigger unit MP10 in accordance with the circuit dia-
gram. Protect the trigger unit with a delayed-action fuse (F) of
max. 4 A. In order to guarantee the protection function, install the
triggerunitastherstelementinthecontrolpowercircuit.